Rotating member and method for coating the same

ABSTRACT

A pulsed discharge is generated between tip ends of a rotating member such as a blade and a discharge electrode including a hard material such as cBN in dielectric liquid or gas by a power supply for discharge to melt the discharge electrode, and a part of the discharge electrode is attached to the tip end of the rotating member to form an abrasive coating film including the hard materials such as cBN.

This is a Continuation-in-Part Application in the United States ofInternational Patent Application No. PCT/JP03/12945 filed Oct. 9, 2003,which claims priority on Japanese Patent Application No. 295964/2002,filed Oct. 9, 2002, and Japanese Patent Application No. 295966/2002,filed Oct. 9, 2002, and Japanese Patent Application No. 167075/2003,filed Jun. 11, 2003. The entire disclosures of the above patentapplications are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The present invention relates to a rotating/rotatable member such as ablade or labyrinth seal for use in a gas turbine, steam turbine,compressor or the like, and a method for coating the rotating/rotatablemember. More particularly, it relates to a rotating/rotatable member ona part of which a coating film including a hard material is formed, anda method for coating the rotating/rotatable member.

2. Description of the Related Art

For a rotating/rotatable member such as a blade or a labyrinth seal, aclearance between a rotating section and a stationary section, such as achip clearance between the blade and a casing or a shroud, or a sealclearance between the labyrinth seal and a honeycomb seal, needs to bekept/set to be appropriate during operation of a gas turbine. When theclearance is set to be excessively large to avoid contact, efficiency ofthe gas turbine drops. Conversely, when the clearance is set to beexcessively small, a tip end of the rotating member breaks and causestrouble for the gas turbine.

Therefore, in consideration of contact of the rotating member withsurrounding members (casing, shroud, honeycomb seal, and the like), atip end of a blade or of a labyrinth seal is coated with an abrasivecoating of a relatively hard material for chipping off the material of acontact surface of the surrounding member. The surrounding member iscoated with an abradable coating of a material, which is relativelyeasily chipped. Accordingly, chip clearance or seal clearance isadjusted so as to be minimized so that a side of the surrounding memberis chipped off by the tip end of the rotating member when driving thegas turbine thereby taking advantage of a hardness difference of thecoatings.

In this case, FIG. 1A is a perspective view of a usual turbine blade,FIG. 1B is a perspective view of the turbine blade with a chip shroud,and FIG. 1C is a perspective view of a compressor blade. It is to benoted that a platform or a dovetail on a turbine disk side is omittedfrom these figures. In a turbine blade 1, shown in FIG. 1A, the wholesurface of a blade tip end is coated with an abrasive coating 5 a. In aturbine blade 2 provided with a chip shroud 3, shown in FIG. 1B, thewhole surfaces of the tip ends of chip fins 4 disposed on a chip shroud3 (i.e., the tip ends of the turbine blade) are coated with abrasivecoatings 5 b. Furthermore, for the blade 1 of the compressor, shown inFIG. 1C, an abrasive coating 5 c is applied over the region of the bladetip end (including the backside of the figure).

Moreover, FIG. 2 is a sectional view showing one example of a labyrinthseal tip end. The labyrinth seal is disposed in the clearance between arotating section and a stationary section to prevent leakage of air orcombustion gas, and is a seal structure frequently used in a gas turbineand compressor. In general, an annular labyrinth seal 6 includingconcave/convex portion is disposed on a rotating section side, and ahoneycomb seal (not shown) including a structure easy to be chipped offis disposed on a stationary section side. FIG. 2 illustrates a sectionalview cut in a plane including a center axis of the labyrinth seal 6, andan abrasive coating 5 d is applied to the tip end of the convex portionof the labyrinth seal 6.

These abrasive coatings have heretofore been applied by methods such aswelding, thermal spraying, and plating (e.g., see References 1 and 2).With respect to coating by welding, a welding rod or a powder body isused to coat predetermined portions, such as the tip end of the turbineblade or the labyrinth seal. With respect to coating by thermalspraying, zirconia is thermally sprayed, which has a small difference inthermal expansion from a mother material and whose hardness isrelatively high (Vickers hardness of 1300 HV). With respect to coatingby plating, abrasive grains (Vickers hardness of 4500 HV) of cubic boronnitride (cBN), which are high in hardness, are electrically attached bynickel plating.

It is to be noted that other prior art methods related to the presentinvention are described in References 3, 4.

[Reference 1]

Japanese Laid-Open Patent Publication No. 11-286768.

[Reference 2]

Japanese Laid-Open Patent Publication No. 2000-345809.

[Reference 3]

Japanese Laid-Open Patent Publication No. 7-301103.

[Reference 4]

Japanese Laid-Open Patent Publication No. 8-319804.

However, in the above-described methods, a portion that does not have tobe coated is masked in order to closely attach the abrasive coating, andthe surface to be coated needs to be blast-treated in order to enhanceadhesion, and there are problems in that there many pretreatments arerequired and costs are high. In either conventional thermal spraying orplating methods, there have been problems in that the adhesion of thecoating is bad, peeling occurs at the time of driving the apparatus,engine trouble is caused, and additionally the chip clearance or theseal clearance is not maintained appropriately. Furthermore, there is aproblem in that, with respect to coating by welding, only a metal muchlower in hardness can be coated as compared to when a ceramic is used,and, therefore, abrasive properties (which are properties for chippingoff a material to be ground) are inferior. Moreover, there is a problemin that the quality level of the coating fluctuates based on theoperator's expertise, and a welding crack may easily occur whenemploying a material poor in thermal conductivity and having smallelongation properties. Furthermore, there has been a problem encounteredin that post-treatments are required, such as processing grinding to arequired dimension after welding so that a lot of trouble is required.

Moreover, according to References 3 and 4, in the coating method,discharge is performed between the rotating member and an electrode onfirst discharge conditions so that the electrode is consumed, and theelectrode is formed in accordance with the shape of a coating filmforming portion. Thereafter, the coating film is formed by dischargebetween the electrode and the rotating member on second dischargeconditions. Then, even when the electrode is not processed beforehandfor a product shape, a coating object portion can still be appropriatelycoated. On the first discharge conditions for consuming the electrode,the electrode is set to have a minus polarity, a pulse width is set to 1μs or less, and a current value is set to 10 A or less. On the seconddischarge conditions for forming the coating film, the electrode ispreferably set to have minus polarity, the pulse width is set to be 2 to10 μs, and the current value is set to be 5 to 20 A.

Moreover, in accordance with conventional abrasive coating, because thewhole area of the tip end of the blade is coated, there has been aproblem encountered in that the coating range is broad and the yield ofproducts is poor.

Furthermore, heretofore, coating has been performed by plating or bythermal spraying. Therefore, during production (manufacturing) of thelabyrinth seal, coating pretreatments, such as a blast process and aprocess of attaching a masking tape, are required before coating isperformed, and coating post-treatments, such as a process of removingthe masking tape, are required after coating is performed. Therefore,the operation time required for the production (manufacturing) of thelabyrinth seal lengthens, and, therefore, it is not easy to improveproductivity of the labyrinth seal.

Additionally, for the same reason, the abrasive coat cannot be firmlyattached to the tip edge of a seal fin. Therefore, a problem has beenencountered in that the abrasive coat easily peels off the tip edge ofthe seal fin and the quality of the labyrinth seal is not stable.

SUMMARY OF THE INVENTION

The present invention has been developed to solve the above-describedvarious problems. In particular, a first object of the present inventionis to provide a rotating/rotatable member that does not require anypretreatment or post-treatment, and which has good adhesion, and whichis coated with a precise abrasive coating of a relatively hard material(hereinafter, referred to as a “hard material” in the presentspecification for the sake of convenience) compared to the material ofan opponent component that contacts with the rotating/rotatable memberduring rotation. In accordance with the first object of the presentinvention, a method for coating the rotating/rotatable member is alsoprovided. Moreover, the first object of the invention is also to providea method for forming a long-service-life coating in tests of high cyclefatigue (HCF) or low cycle fatigue (LCF) for an abrasive coatedcomponent.

Furthermore, a second object of the present invention is to provide arotating/rotatable member wherein the area of coating of the hardmaterial is optimized to enhance the yield and to provide a method forcoating the rotating member in accordance with the second object of theinvention.

Additionally, a third object of the present invention is to provide arotating/rotatable member in which the operation time required forproduction of a labyrinth seal is reduced and in which productivity oflabyrinth components can be improved. In accordance with the thirdobject of the present invention, a method for coating therotating/rotatable member is provided.

To achieve the first object, according to a first invention, there isprovided a method for coating a rotating/rotatable member, comprisingthe steps of: generating a pulsed discharge between a rotating/rotatablemember formed into a predetermined shape and a discharge electrode of agreen compact in dielectric liquid or gas to transfer a hard material ofthe discharge electrode or a hard material changed from a material ofthe discharge electrode onto the rotating/rotatable member by eachdischarge pulse so that a hard concavity and convexity is formed on therotating/rotatable member, wherein the green compact includes the hardmaterial or the material changing into the hard material by thedischarge; and repeatedly generating the discharge pulse to form on therotating/rotatable member a hard coating film having concavity andconvexity.

Moreover, according to a second invention, in the method for coating therotating/rotatable member, the hard coating film is an abrasive coatingfilm that is formed on a part of the rotating/rotatable member and thatrubs against and shaves an opponent component.

According to the first and second inventions, because the so-called“discharge coating method” is used, pretreatments such as masking andblast treatment or post-treatments such as grinding are not necessary.Furthermore, the coating film or a layer having good adhesion can beformed and used as a coating, and the coating film contains remarkablyhard materials such as a cubic boron nitride (cBN), and a hard coatingfilm and a coating film having good abrasive properties can be formed.Abrasive properties of the coating are improved by treatment on acondition for forming a coating having a coarse surface.

Moreover, according to a third invention, the method comprises the stepsof: generating a discharge between the rotating/rotatable member and thedischarge electrode on a first discharge condition on which thedischarge electrode is consumed so that the shape of the dischargeelectrode is made to conform to the shape of the coating film formingportion on the rotating/rotatable member; and, thereafter generating adischarge between the discharge electrode and the rotating/rotatablemember on a second discharge condition to form the coating film on therotating/rotatable member.

Furthermore, according to a fourth invention, preferably, on the firstdischarge condition, the discharge electrode has a minus polarity, apulse width of 1 μs or less, and a current value of 10 A or less, and onthe second discharge condition, the discharge electrode has a minuspolarity, the pulse width is 2 to 10 μs, and the current value is 5 to20 A. Additionally, the coating film is preferably formed on the tip endof the rotating/rotatable member. Furthermore, for the hard member, asin an eighth invention, the discharge electrode of the green compactcontains one of, or a mixture of, cBN, TiC, TiN, TiAlN, TiB₂, WC, Cr₃C₂,SiC, ZrC, VC, B₄C, Si₃N₄, ZrO₂—Y, and Al₂O₃. Moreover, the materialforming the hard member by the discharge is preferably one of, or amixture of, Ti, Cr, W, V, Zr, Si, Mo, and Nb, and these materials areformed into carbide by the discharge in an oil in order to form the hardcoating film. Because a so-called “discharge coating method” is usedaccording to this method, the tip end of the rotating/rotatable membercan easily be coated with the hard material. From the viewpoint ofresistance to oxidation, a coating film containing TiC, WC, or cBN ispreferably formed on the rotating/rotatable member that is driven at alow temperature, and a coating film containing cBN or Cr₃C₂ is used inthe rotating member that is driven at a high temperature, and a coatingfilm containing ZrO₂—Y or Al₂O₃ is formed on the rotating/rotatablemember that is driven at an even further higher temperature.

According to a fifth, sixth, seventh, and ninth inventions, there isprovided a method of enhancing fatigue strength of a coated surface. Acoating film that does not easily stretch, as compared with a mothermaterial, is formed on the surface. Then, because a thin coating filmbears a tensile load, the coating film on the surface cracks easily.When coating by a discharge surface treatment, because the hard layer isfirmly welded to the mother material, cracking of the coating filmdevelops into cracking of the mother material. To avoid this cracking,it is necessary to form a coating film having ductility, or to form alayer for preventing the development of cracks between the mothermaterial and the coating film, or to form a coating layer that is strongagainst pull forces.

In accordance with a fifth invention, in the coating film, a ratio of acoated area coated with the hard material in a coating film formingportion to a portion not coated with the hard material in the coatingfilm forming portion is such that coverage is suppressed, wherein thenot coated portion providing ductility is scattered and left in thecoated area (FIG. 4), and thereby ductility is provided for the coatingfilm.

In a sixth invention, the discharge electrode is made to contain a metalthat does not easily form carbide. Accordingly, a portion of the metalthat does not easily form carbide is scattered in the coating film andhas ductility, and by forming a portion between the hard materialsductility is provided to the coating film.

In accordance with a seventh invention, a porous coating film, mainlyformed of a metal, is formed as a base. Thereafter, since the coatingfilm containing the hard material is formed on the porous coating film,cracking of the coating layer is prevented from developing into crackinginto the mother material.

In accordance with a ninth invention, the surface of the coating layeris peened, and residual stress of compression persists after peening.Thus, even when the mother material stretches, tensile stress isreduced.

These fifth to seventh, and ninth inventions are effective not only forforming a coating with hard material but also for the discharge surfacetreatment for forming the coating film on the surface, such as whenforming a wear-resistant coating.

Moreover, according to the eighth invention, because a remarkably hardceramic, usable in the coating of the hard material, is provided, it ispossible to provide a coating formed of an effective hard material.

Furthermore, according to a tenth invention, a rotating/rotatable memberis provided having an abrasive coating film formed on a part thereofthat is formed by a pulsed discharge between the rotating/rotatablemember and a discharge electrode of a green compact in dielectric liquidor gas, wherein the green compact includes a hard material or a materialthat changes into a hard material by the discharge, and the abrasivecoating film includes the hard material of the green compact or the hardmaterial that is changed from the material of the green compact by thedischarge. The rotating/rotatable member is characterized in that thepretreatments, such as a masking or a blast process, or thepost-treatments, such as grinding, are not necessary and the coatingfilm or the layer having good adhesion is formed. Furthermore, thecoating film is preferably formed on the tip end of therotating/rotatable member.

For the rotating/rotatable member, the discharge is caused between therotating/rotatable member and the discharge electrode in the dielectricliquid or gas to form an abrasive coating film, including the hardmaterial, on a part of the rotating/rotatable member so that therotating/rotatable member is formed to be superior in abrasiveproperties.

According to the eleventh to fourteenth inventions, because the coatingfilm having ductility is formed, the layer for preventing development ofcracks is formed between the mother material and the coating film, andthe coating layer, which is strong against pull forces, is formed sothat the rotating member is provided with a high fatigue strength.

Moreover, according to a fifteenth invention, a remarkably hard ceramic,usable in the coating of the hard material, is provided and,accordingly, the rotating/rotatable member is provided with goodabrasive properties.

To achieve the second object, according to a 16th invention, there isprovided a rotating/rotatable member wherein only the vicinity of aportion of the rotating/rotatable member that has a possibility ofcoming into contact with a component disposed opposite to therotating/rotatable member is coated with hard material. Accordingly, arotating/rotatable member is obtained that requires little in labor ofoperation, is small in the amount of electrode use, exhibits a goodyield of products, and that is low in cost.

In accordance with a 17th invention, there is provided a furtherinexpensive rotating/rotatable member wherein the range of area to becoated is locally limited.

In accordance with an 18th invention, a rotating/rotatable member isprovided that is coated in a method for enhancing the abrasiveproperties of the tenth to 17th inventions. The rotating/rotatablemember is coated under conditions for forming a coarse surface roughnessin order to enhance the abrasive properties of the coated rotatingmember.

A 19th invention provides a concrete example of the 16th invention,wherein there is provided a blade whose tip end is coated with hardmaterial. Only a corner of the blade in a rotation advance direction anda portion in the vicinity of the corner are coated with the hardmaterial. Because the range of the coating of the hard material isoptimized, the yield is improved, the operation time is shortened, andthe coating material can be coated efficiently without waste.

A 20th invention provides a concrete example of the 17th invention,wherein a rotating/rotatable member is provided in which the coatingfilm is formed on not all, but some of the blades of a rotor or a blisk.By minimizing the number of coated blades, operation time is reduced andcoating material can be coated even more efficiently with even lesswaste.

To achieve a third object, in accordance with a 21st invention, therotating/rotatable member is a rotating/rotatable labyrinth sealcomponent that is one of the structure elements of a labyrinth sealstructure that suppresses leak of a gas or liquid between a stationarycomponent and a rotating component. The rotating/rotatable membercomprises an annular seal component main body, and an annular seal finintegrally formed on an outer peripheral surface of the seal componentmain body, and a tip edge of the seal fin is coated with hard material.For forming a coat of the hard material, an electrode for coating havingconsumability is used, a pulsed discharge is caused between theelectrode for coating and the tip edge of the seal fin in dielectricliquid or gas, and the coat includes the hard material formed of aconstituting material of the electrode for coating formed on the tipedge of the seal fin by discharge energy or of a reactant of theconstituting material.

In this disclosure, in general, the phrase “electrode for coating havingconsumability” means a green compact electrode (including a thermallytreated green compact electrode) obtained by compression molding of apowdered metal (including a metal compound), a mixed material of thepowdered metal and a powdered ceramic, or a powdered ceramic havingconductivity. Furthermore, the phrase “electrode for coating havingconsumability” also means a silicon electrode formed of solid silicon.It is to be noted that, in accordance with the present invention, theceramic having conductivity is appropriately subjected to a surfacetreatment.

According to a 21st invention, the coat of hard material is a coatingfilm including a hard material constituted of the constituting materialof the electrode for coating, or a reactant of the constitutingmaterial, formed on the tip edge of the seal fin by discharge energygenerated between the electrode for coating and the tip edge of the sealfin without performing plating or thermal spraying. Therefore, duringproduction of the rotating/rotatable labyrinth seal component, coatingpretreatments, such as a blast treatment and a process of attaching amasking tape, and coating post-treatments, such as a process of removingthe masking tape, are unnecessary.

Moreover, because a boundary portion between the coat of the hardmaterial coated by discharge energy and a mother body of the seal finhas alloy composition changing properties (i.e., alloy compositionchanges depending on the position), the coat of hard material can befirmly connected to the tip edge of the seal fin.

Furthermore, in accordance with the 21st invention, preferably as in the22nd invention, the coat of hard material includes a plurality of localcoating films locally formed on a plurality of portions in a peripheraldirection to the tip edge of the seal fin. By this constitution, thecoat of hard material includes a plurality of local coats. In otherwords, the coating film including hard material constituted of theconstituting material of the electrode for coating, or the reactant ofthe constituting material, is locally formed on a plurality of portionsof the peripheral direction in the tip edge of the seal fin, but not inthe whole periphery of the tip edge of the seal fin. Therefore, theelectrode for coating can be formed in a small and simple shape inaccordance with the size or the shape of the portion to be treated ofthe tip edge of the seal fin. Moreover, the amount of electrode materialused from the electrode for coating can be reduced.

It is to be noted that, as described above, because the coat of hardmaterial (i.e., the local coat of hard material) can be connected firmlyto the tip edge of the seal fin, the entire rotating/rotatable labyrinthseal component can be provided with sufficient abrasive properties byjust the local coat of the plurality of hard materials without having tocoat the whole periphery of the tip edge of the seal fin with hardmaterial.

Furthermore, in accordance with the tenth invention, preferably as inthe 15th invention, the electrode for coating is the green compactelectrode obtained by compression molding of powdered metal, the mixedmaterial of the powdered metal and the powdered ceramic, or the powderedceramic having conductivity, or the solid silicon electrode.Furthermore, the ceramic is one of, or a mixture of, cBN, Cr₃C₂, TiC,TiN, TiAlN, TiB₂, ZrO₂—Y, ZrC, VC, B₄C, WC, SiC, Si₃N₄, and Al₂O₃.

In accordance with this disclosure, the “powdered metal” also includes apowdered metal compound. It is to be noted that, in accordance with thepresent invention, a ceramic that does not have conductivity may beappropriately subjected to a surface treatment so as to secureconductivity.

Moreover, in accordance with a 23rd invention, there is provided alabyrinth seal structure that suppresses a leakage of a gas or liquidbetween a stationary component and a rotating component, comprising: astationary-side seal component integrally disposed on the stationarycomponent; an annular seal component main body that is disposed insidethe stationary-side seal component and that is capable of rotatingintegrally with the rotating/rotatable component and which is integrallydisposed on the rotating/rotatable component; an annular seal finintegrally formed on an outer peripheral surface of the seal componentmain body; and a hard coat formed on the tip edge of the seal fin,wherein the hard coat is a coating film including a hard materialconstituted of a constituting material, or a reactant of theconstituting material, of an electrode for coating formed on the tipedge of the seal fin by discharge energy of a pulsed discharge betweenthe electrode for coating and the tip edge of the seal fin, and theelectrode for coating has consumability.

In this disclosure, the phrase “stationary-side seal component” includesa honeycomb-shaped stationary honeycomb seal component, or a stationaryabradable seal component whose inside is coated with an abradable coat.Moreover, in general, the phrase “electrode for coating havingconsumability” means a green compact electrode (including a thermallytreated green compact electrode) obtained by compression molding of apowdered metal (including a metal compound), a mixed material of apowdered metal and a powdered ceramic, or a powdered ceramic havingconductivity. Furthermore, the phrase “electrode for coating havingconsumability” also means a silicon electrode formed of solid silicon.It is to be noted that for ceramic that does not have conductivity, thesurface of a ceramic powder that does not have conductivity is thensubjected to a treatment for forming a conductive coating film so as toappropriately secure conductivity for the ceramic powder.

According to the 23rd invention, the rotating/rotatable labyrinth sealcomponent includes a coat of hard material. Therefore, when integrallyrotating the rotating/rotatable labyrinth seal component with therotating/rotatable component, even when the stationary-side sealcomponent is deformed, when the rotating/rotatable labyrinth sealcomponent contacts the stationary-side seal component, thestationary-side seal component is simply shaved by the coat of hardmaterial in the rotating/rotatable labyrinth seal component, whereas therotating/rotatable labyrinth seal component is hardly shaved at all.

Accordingly, the clearance between the stationary-side seal and therotating/rotatable labyrinth seal component is inhibited from increasingduring rotation of the rotating/rotatable component, and the seal effectof the labyrinth seal structure can be kept in an appropriate state.Moreover, the rotating/rotatable labyrinth seal component is set so asto slightly contact with the stationary-side seal component duringinitial rotation of the rotating/rotatable component. Accordingly,during or after the initial rotation, the clearance between thestationary-side seal component and the rotating/rotatable labyrinth sealcomponent can be reduced as much as possible, and the seal effect of thelabyrinth seal structure can be further enhanced.

Moreover, the coat of hard material is a coating film, including thehard material constituted of the constituting material of the electrodefor coating or of the reactant of the constituting material, that isformed on the tip edge of the seal fin by discharge energy generatedbetween the electrode for coating and the tip edge of the seal finwithout performing plating or thermal spraying. Therefore, duringproduction of the rotating/rotatable labyrinth seal component, thecoating pretreatments, such as the blast treatment and the process ofattaching the masking tape, and the coating post-treatments, such as theprocess of removing the masking tape, are unnecessary. Furthermore,because the boundary portion between the coat of hard material coated bydischarge energy and the mother material of the seal fin has alloycomposition changing properties, the coat of hard material can beconnected firmly to the tip edge of the seal fin.

Furthermore, in accordance with a 24th invention, preferably the coat ofhard material includes a plurality of local coating films locally formedon a plurality of portions in the peripheral direction of the tip edgeof the seal fin. By this constitution, the coat of hard materialincludes a plurality of local coats of hard material. In other words,the coating film, which includes hard material constituted of theconstituting material of the electrode for coating or the reactant ofthe constituting material, is formed locally on a plurality of portionsto be treated in the peripheral direction of the tip edge of the sealfin, and not in the whole periphery of the tip edge of the seal fin.Therefore, the electrode for coating can be formed into a small andsimple shape in accordance with the size or shape of the portion to betreated in the tip edge of the seal fin. Moreover, the amount of theelectrode material used by the electrode for coating can be reduced.

It is to be noted that, as described above, because the coat of the hardmaterial (i.e., the local coat of hard material) can be firmly connectedto the tip edge of the seal fin, the entire rotating/rotatable labyrinthseal components can be provided with sufficient abrasive properties bylocal coats of the plurality of hard materials without coating the wholeperiphery of the tip edge of the seal fin with hard material.

In accordance with a 25th invention, there is provided a method formanufacturing a rotating/rotatable member of a blade or a labyrinthmember, comprising: a first step of forming a forged material or acasted material into a predetermined shape by mechanical processing; anda second step of generating a pulsed discharge between arotating/rotatable member formed into a predetermined shape and adischarge electrode of a green compact or solid silicon in dielectricliquid or gas in order to transfer hard material of the dischargeelectrode or hard material changed from a material of the dischargeelectrode onto the rotating/rotatable member by each discharge pulse sothat a hard concavity and convexity is formed on the rotating/rotatablemember, wherein the green compact includes the hard material or thematerial changing into the hard material by the discharge, andrepeatedly generating the discharge pulse to form on therotating/rotatable member a hard coating film having the concavity andconvexity.

In accordance with a 26th invention, in the above-describedmanufacturing method, in the second step, an abrasive coating film,which rubs against and shaves an opponent component, is formed as thehard coating film on a part of the rotating/rotatable member.

In accordance with a 27th invention, there is provided a method formanufacturing the rotating/rotatable member, wherein the second stepcomprises the steps of forming a discharge electrode into a shape inaccordance with the shape of a predetermined portion of therotating/rotatable member.

In accordance with a 28th invention, there is provided a method forproviding discharge conditions so that the shape of the dischargeelectrode conforms to that of the coating film forming portion of therotating/rotatable member in order to form the electrode without anytrouble.

In accordance with a 29th invention, there is provided a method formanufacturing the rotating/rotatable member so that therotating/rotatable member does not easily collapse from fatigue, whereinduring the formation of the coating film in the second step, a dischargecondition is controlled to set a coverage to be 95% or less in thecoating film forming portion, wherein the coverage is a ratio of an areaat which the coating film including the hard material is formed.

In accordance with a 30th invention, there is provided a method ofmanufacturing the rotating/rotatable member, wherein the ratio of thecoverage is controlled to provide the rotating/rotatable member with thecharacteristic that it does not easily collapse from fatigue.

In accordance with a 31st invention, there is provided a method formanufacturing the rotating/rotatable member so that therotating/rotatable member does not easily collapse from fatigue, whereinin the second step, a green compact electrode containing 5% or more byvolume of a metal that does not easily react into carbide is used toperform the discharge.

In accordance with a 32nd invention, there is provided a method formanufacturing the rotating/rotatable member so that therotating/rotatable member does not easily collapse from fatigue, whereinthe second step comprises the steps of: forming a porous coating film ona coating film forming portion of the rotating/rotatable member; andthereafter forming the coating film including the hard material on theporous coating film. In accordance with a 33rd invention, there isprovided a method for manufacturing the rotating/rotatable member thatis superior in abrasive properties by using the appropriate dischargeelectrode material of the green compact in the second step.

In accordance with a 34th invention, there is provided a method ofmanufacturing the rotating/rotatable member so that therotating/rotatable member does not easily collapse from fatigue, furthercomprising: a third step of subjecting the coating film formed in thesecond step to a peening treatment.

Other objects and advantageous characteristics of the present inventionwill be apparent from the following description with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a typical turbine blade, FIG. 1B is aperspective view of the turbine blade provided with a chip shroud, andFIG. 1C is a perspective view of a compressor blade;

FIG. 2 is a perspective view showing one example of a conventionallabyrinth seal tip end;

FIG. 3 is a diagram showing a first embodiment of a rotating/rotatablemember and coating method of the present invention;

FIG. 4 is a diagram showing a second embodiment of the rotating/rotatabemember and coating method of the present invention;

FIG. 5 is a diagram showing a third embodiment of the rotating/rotatablemember and coating method of the present invention;

FIG. 6 is a diagram showing a fourth embodiment of therotating/rotatable member and coating method of the present invention;

FIGS. 7A, 7B, and 7C are perspective views of the turbine bladeaccording to a fifth embodiment of the rotating/rotatable member of thepresent invention;

FIGS. 8A, 8B, and 8C are perspective views of the turbine blade providedwith a chip shroud according to a sixth embodiment of therotating/rotatable member of the present invention;

FIGS. 9A, and 9B, are perspective views of the compressor bladeaccording to a seventh embodiment of the rotating/rotatable member ofthe present invention;

FIG. 10 is a diagram showing the fifth embodiment of the coating methodaccording to the present invention;

FIG. 11 is a schematic diagram of a labyrinth seal structure accordingto an eighth embodiment of the rotating/rotatable member of the presentinvention;

FIG. 12 is a front view of a labyrinth seal of FIG. 11; and

FIG. 13 is a schematic diagram of a discharge processing machineaccording to the eighth embodiment of the coating method according tothe present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Preferable embodiments of the present invention will hereinafter bedescribed with reference to the drawings. It is to be noted thatcomponents common to the respective drawings are denoted with the samereference numerals, and redundant description is omitted.

FIG. 3 is a diagram showing a first embodiment of a rotating/rotatablemember and coating method of the present invention. This figure showsthat the tip end of blade 1, for use in a gas turbine or a compressor,is coated with a hard material.

In the method of the present invention, as shown in FIG. 3, the blade 1and a discharge electrode 11 that includes cubic boron nitride (cBN) aresubmerged in a processing tank 12 filled with dielectric liquid (oil). Apulsed discharge is caused between the tip end of the blade 1 and thedischarge electrode 11 by a power supply for discharge 14 in order tomelt the discharge electrode 11. A part of the electrode is consequentlywelded to the tip end of the blade 1 to form a cBN-containing coatingfilm 10. In this case, only sections of the blade 1 and dischargeelectrode 11 are shown, however, the blade 1 is fixed by a blade fixingjig, and the discharge electrode 11 is fixed by an electrode fixing jig(not shown). It is to be noted that FIG. 3 shows an example of theblade, but a labyrinth seal, which is the same kind ofrotating/rotatable member, can also be coated with hard material inaccordance with a similar method. It is to be noted that, in the figure,reference numeral 13 denotes the blade fixing jig.

In accordance with the above description, cBN is used as a hardmaterial, and cBN is a coating material optimum for a turbine blade thatis exposed at high temperature in that Vickers hardness is 4500 HV atroom temperature, and Vickers hardness close to 2000 HV can bemaintained even at high temperature of 900° C. or more. Additionally,from the viewpoint of resistance to oxidation, hard material of TiC, WCcan be used in those rotating members used at a low temperature, Cr₃C₂can be used in those rotating members for use at a high temperature, andZrO₂—Y or Al₂O₃ can be used in those rotating/rotatable members for useat an even further high temperature. Therefore, according to the presentinvention, a coating film containing TiC, WC, or cBN is formed on therotating/rotatable member for use at low temperature, a coating filmcontaining cBN or Cr₃C₂ is used in rotating/rotatable members for use athigh temperature, and a coating film containing ZrO₂—Y or Al₂O₃ isformed on the rotating/rotatable member for use at even further hightemperature. Needless to say, these hard materials may also be mixedtogether to form an optimum coating film. It is to be noted that adischarge coating technique is disclosed, for example, in “SurfaceTreatment Method of Metal Material by In-liquid Discharge” of JapaneseLaid-Open Patent Publication No. 7-197275, and the description providedtherein is omitted.

In accordance with the present invention, because ceramics, such as cBN,are hard insulating materials, a single ceramic such as cBN cannot beformed into the discharge electrode, but the discharge electrodecontaining such ceramics (such as cBN) can be formed by use of aconductive binder. For example, Co-based alloy powder can be used as theconductive binder, and ceramic powder such as cBN may be mixed with theCo-based alloy powder, charged in a press mold, and compressed/molded.It is to be noted that the amount of binder is preferably about 50% ormore by a volume ratio of the mixture.

Furthermore, a powder of ceramics, such as cBN, may be coated withtitanium (Ti), nickel (Ni), or cobalt (Co), which is a binder used toform the discharge electrode. A particle diameter of the whole powderneeds to be smaller than the pole distance between the electrode and thework undergoing the discharge surface treatment, and is, therefore,preferably about 10 μm or less. The powder of ceramics, such as cBN, canbe easily coated with a thin coating film of Ti, Ni, or Co metal byvapor deposition.

When the conductive binder is mixed, and the discharge electrodecontaining ceramics, such as cBN, is formed in this manner, a dischargecan be caused in a portion of the binder so that the discharge electrodeis brought into a molten state by heat energy, and a part of thedischarge electrode can then be welded/attached to the tip end of therotating member, such as the blade. As a result, the tip end of therotating/rotatable member can be coated with a hard coating filmcontaining ceramics such as cBN.

Here, Table 1 shows results of a wear test in which two test pieces(upper and lower test pieces), wherein only the lower test piece iscoated by the coating method of the present invention, are ground(rubbed) with each other at high temperature.

TABLE 1 Coating material Wear amount (μm) Upper test piece Ni alloy 600or more Lower test piece cBN coating 0

The upper test piece is RENE77, which is a nickel-based alloy, and thelower test piece is cBN, which is a coating film made in accordance withthe present invention. For test conditions, the conditions employed weretemperature: 800 degrees centigrade; surface pressure: 7 Mpa; cyclenumber: 10⁷ cycles; and amplitude: 0.35 mm. As seen from Table 1, a wearamount of 600 μm or more is measured on the Ni alloy, but no wear isdetected on the coating film of cBN. From this result, it is seen thatcBN is superior in abrasive properties because it wore down the Nialloy. It is to be noted that the Ni alloy of the upper test piece is analloy constituted of a component ratio of Ni: 57%, Cr: 15%, Co: 15%, Mo:5%, Ti: 3.5%, Al: 4.4, C, 0.1%.

When a so-called discharge coating method is used to coat the tip end ofthe rotating/rotatable member, such as the blade, with the coating filmcontaining ceramics such as cBN, the hard coat can be applied easily byuse of characteristics of the ceramics such as cBN, and a coating film,having good adhesion and quality level, can be coated as compared toconventional methods such as by welding and by thermal spraying.According to the present invention, because a thin coating film (or alayer) having a thickness of several microns to 30 μm can be formed, thecoating film is not easily cracked, and precision of the thickness canbe controlled by a unit of several μm. Therefore, it is possible toprovide a coating method optimum for precision components, such as theblade and labyrinth seal.

Coarser surface roughness, corresponding to abrasive properties forshaving the opponent component to be ground, is preferable. In the aboveexample, the surface roughness is coarser than 1.2 μmRa.

As described above, because the so-called discharge coating method isused in the present invention, pretreatments (such as the masking andblast process) are unnecessary, and a coating film having good adhesioncan be easily and inexpensively formed. Furthermore, a coating filmcontaining ceramics, such as cubic boron nitride (cBN), can be coated.Therefore, a portion of the rotating/rotatable member requiring abrasiveproperties can be coated with a hard coating film that is superior inabrasive properties.

A coating layer of the hard material is hard, but has little ductility.Therefore, a tensile stress applied to the component coated with thehard material is not borne by the mother material of the component whenthe component has a large ductility. Instead, the tensile stress isborne only by the coating layer of the surface, which coats thecomponent. Therefore, the surface (i.e., the coating layer) cracks, andthere is a possibility that the crack will develop into the mothermaterial. To avoid this cracking, a method of imparting ductility to theotherwise hard coating layer is used.

Table 2 shows the number of cycles reaching destruction in a high cyclefatigue (HCF) test in which an outer diameter of a round rod is coatedwith the hard material and a tensile load is going to be repeated in anaxial direction. Without any coating of hard material, the round rodmaterial does not break up to one million cycles. However, when acoating in which the ratio of coated area coated with hard material ofthe coating surface is 98% (that is, when the ratio of coverage ofcoated portions 100 to uncoated portions 101 of an area coated with thecoating film is 98% of the coated surface (i.e., coated area) instead of95% or less as shown in FIG. 4), the round rod material is observed tobreak at 20 thousand cycles. However, when the coverage is decreased toabout 95%, as shown in Table 2, the round rod material does not break upto one million cycles.

TABLE 2 Coating state Cycle number of break No coating One millioncycles 98% coverage of TiC 20 thousand cycles 95% coverage of TiC Onemillion cycles HFC test conditions: 500° C., 650 MPa, pull of round rodhaving a diameter of 5 mm in axial direction at 30 Hz

When the coverage of the coating is lowered to 95% or less, the abrasiveproperties of the whole coating surface are slightly sacrificed in orderto increase the ductility of the coating surface. When the coverage israised, ductility decreases as evident from Table 2, and fatiguestrength drops. However, at 95% coverage, fatigue strength does not dropin a large manner (if at all), although the abrasive properties of thecoating surface drop a little. In accordance with one method of thepresent invention for lowering the coverage, discharge time is reducedto a range in which complete discharge does not occur, and in this waythe coverage can be reduced. The coating treatment is usually performedfor a time of five minutes/square centimeter, but the time may bereduced to about 3.8 minutes/square centimeter.

A calculation equation is as follows:

Time for obtaining a coverage of 95%=time for obtaining a coverage of98%*LOG(1−0.95)/LOG(1−0.98). A coverage of 98% is regarded as a coverageof 100% for the purpose of the calculation equation. To calculate thetime from a time for obtaining a coverage of 50%, 0.98 in LOG(1−0.98) ischanged to 0.5.

In another method, as shown in FIG. 5, by the use of an electrode towhich metal powder, which is of a type that is not easily carbonized, isadded, ductile properties of the metal may be imparted to the coatinglayer. When the electrode contains 5% or more of such a metal that isnot easily carbonized, 5% or more of a portion having the ductility inthe coating layer remains, and an effect similar to that of Table 2 canbe expected. Also in this method, the abrasive properties of the wholecoating surface are slightly sacrificed in order to enhance theductility of the coating layer. Examples of metals that are not easilycarbonized include cobalt, nickel, and iron. With respect to coverage,one blade has been described. However, there are a large number ofblades in a turbine. Therefore, even if the coverage of the coatinglayer is low, or even if the abrasive properties are not observed in acertain portion of a certain blade, the other blades can cover theabrasive properties. This principle also applies to an annular sealbecause if one portion on the circumference of the annular seal has theabrasive properties, it is possible to obtain abrasive properties forthe annular seal (See, e.g., FIG. 12).

Moreover, as still another method of preventing cracking, as shown inFIG. 6, a porous layer is formed as a base for the coating layer of hardmaterial in order to prevent the cracking of the coating layer fromdeveloping and then progressing into the mother material. The porouslayer is formed as a base, and is disposed under the coating layer,which is formed on the porous layer. This base is also formed bydischarge coating. The porous layer having a thickness of 0.05 mm ormore can be formed by using a second electrode obtained by compressionmolding of a powder of metals such as Stellite. Thereafter, the porouslayer is coated with hard material.

Moreover, the surface of the coating of the hard material is peened sothat the surface is accordingly stretched, and compression stressremains so that tensile stress is reduced even when the mother materialis elongated. The fatigue strength can thus be enhanced by the effect ofpeening.

FIGS. 7A to 7C, 8A to 8C, 9A and 9B are perspective views showing fifthto seventh embodiments of the rotating/rotatable member of the presentinvention. It is to be noted that in these figures, a platform or adovetail on a disk side is omitted from the drawings.

In the turbine blade 1 of FIG. 7A, the corner of the blade in a rotationadvance direction (that is, the blade tip end of the blade surface onthe back side), and a tip end surface are coated with a coating 20 ofhard material. In a thin turbine blade of FIG. 7B, the blade tip end ofthe blade surface on the back side and the entire tip end surface arecoated, and the opposite surface may not be coated. In the turbine bladeof FIG. 7C, the blade tip end of the blade surface on the back side iscoated, and the entire tip end surface is not coated.

In the turbine blade 2 provided with a chip shroud, as shown by FIG. 8A,the corner of the tip end of a chip fin 4 in the rotation advancedirection, or the surface of the chip fin 4 in the rotation advancedirection (that is, the backside surface of the tip end of the chip fin4) are coated with a coating 21 of hard material. It is to be noted thatthe chip shroud 3 is disposed to prevent resonance of the blades 2 atthe time of high-speed rotation of the gas turbine and to prevent ahigh-temperature gas from leaking to the outside of the blades 2.

For a small blade, as shown by FIG. 8B, the entire surface of the tipend and the surface of the rotation advance direction (i.e., on thebackside surface of the tip end of the chip fin 4) are coated, and theopposite surface may not be coated. In the turbine blade of FIG. 8C, thesurface of the rotation advance direction (i.e., the backside surface ofthe tip end) is coated, and the whole surface of the tip end is notcoated.

In the compressor blade 1 of FIG. 9A, the corner of the blade in therotation advance direction (that is, the blade tip end of a bladesurface on the front side) and the tip end surface are coated with acoating 22 of hard material. In the compressor blade of FIG. 9B, thesurface of the rotation advance direction (that is, the blade tip end ofa blade surface on the front side is coated), and the entire surface ofthe tip end is not coated.

In the blades of FIGS. 9A and 9B, an abrasive property test was carriedout by simulation of an actual device, wherein a difference was notobserved in the abrasive property. As described above, the coating ofhard material is applied so as to shave the abradable coating of theopposite component by using the tip ends of the blades 1, 2 therebytaking advantage of the hardness difference, at the time of driving theblades 1, 2, to maintain a minimum chip clearance. The abradable coatingis applied on the casing or the shroud (i.e., opposite components).Moreover, this phenomenon starts by contact occurring between thecasing, or the shroud, and the corners of the blades 1, 2 in therotation advance direction, and the phenomenon ends when the casing orthe shroud is shaved by the corners of the blades 1, 2. That is, aftercontact of the corner with the casing or shroud, another portion of thesame blade hardly contacts the casing or the shroud. In consideration ofthis fact, the coating of hard material does not have to be applied overthe entire region of the blade tip end as in the related art discussedabove. As described in accordance with the present invention, it issufficient that only a range of contact with the abradable coating (thatis, only the corner of the rotation advance direction, or only thesurface of the rotation advance direction of the blade that contacts thecasing or shroud) is coated with coatings 20, 21, 22 of hard material.When the range of the portion of the blade to be coated is optimized inthis manner, the range to be coated is narrowed, so the yield ofproducts is increased, the operation time can be shortened, expensivecoating material can be saved instead of wasted, and cost can bereduced.

FIG. 10 is a diagram showing a fifth embodiment of the coating methodaccording to the present invention, and is a diagram showing the coatingmethod of the blades shown in FIGS. 7A to 7C. In the coating method ofthe present invention, the blade 1 and a discharge electrode 23 aresubmerged in the processing tank 12 filled with the dielectric liquid(oil), the discharge electrode 23 is disposed in the vicinity of thecorner in the rotation advance direction of the blade 1, a discharge iscaused between them, and only the corner of the blade 1 in the rotationadvance direction is coated with the coating 20 of hard material.

The coating 20 of hard material is formed to have a very thin thicknessof 10 to 20 μm (exaggerated in the figure for ease of seeing the coating20 in the figure). Therefore, after molding the blade 1 as usual, it issufficient to apply the coating 20 of hard material only to a portion ofcontact with the opposite member (that is, only the corner of therotation advance direction or the surface of the rotation advancedirection). Needless to say, the corner of the blade 1 is shaved by thethickness of the coating 20 of hard material by machine processing, anda casting mold taking into consideration beforehand the thickness of thecoating 20 may be used to mold the blade 1.

Moreover, in the case of a thin blade, the coating of hard material maybe formed entirely on the rotation advance direction surface and on thetip end surface. However, the surface disposed opposite to the rotationadvance direction surface does not have to be coated.

It is to be noted that only the sections of the blade 1 and dischargeelectrode 23 are shown in FIG. 10. In accordance with this coatingmethod of the present invention, a discharge electrode 23 shaped so asto coat only the blade tip end of the blade surface on the back side andon the tip end surface is preferably used so that only the corner of theblade 1 in the rotation advance direction is subjected to the dischargecoating. For example, the discharge electrode 23 has a substantiallyL-shaped section, and a shape curved along the back side of the blade asshown in FIG. 10.

The electrode may be processed beforehand into a product shape. However,alternatively, the electrode may be formed in accordance with theproduct shape by discharge on the discharge condition in which theelectrode is easily consumed. Under this condition, the electrode is setto have a minus polarity, and the discharge is caused on a comparativelysmall energy condition on which the pulse width is set to 1 μs or less,and the current value is 10 A or less. In this way, damage of theproduct is suppressed, and the electrode can accord with the productshape. When the coating film is formed, the electrode is assumed to havethe minus polarity, and the discharge is caused under a comparativelylarge energy condition in which the pulse width is about 2 to 10 μs, andthe current value is about 5 to 20 A.

It is to be noted that although not shown, for the turbine bladeprovided with the chip shroud 2, as shown in FIGS. 8A to 8C, such anelectrode may be used to coat the corner of the chip fin 4 in therotation advance direction.

In discharge coating, the discharge is caused on the surfaces disposedopposite to each other by application of a voltage between the blade 1and the discharge electrode 23 submerged in dielectric liquid.Consequently, the surface of the discharge electrode 23 is molten by thedischarge, and the molten element is attached on the surface of theblade 1 to form the alloy on the surface. A solidified coating materialis used for the material of the discharge electrode 23.

Because the thickness of the coating can be controlled to the degree ofseveral micrometers, discharge coating is a coating method optimum forcoating precision components such as the blade 1. Moreover, those placeswhere the discharge does not occur are not coated. Therefore, becausethe portion to be coated can be coated locally, the pretreatments (suchas masking) are unnecessary. Because heat generation is small, the bladeis not thermally deformed, and consequently post-treatment is alsounnecessary.

As described above, in accordance with the present invention, becausethe coating range of the hard material is optimized, the yield ofproducts can be enhanced. Because operation time can be shortened, andthe coating material can be used without waste, the cost of productioncan be reduced. Furthermore, because the so-called discharge coating isused, only the corner of the rotation advance direction of the blade, orthe surface of the rotation advance direction, is easily andinexpensively coated with the hard material.

Moreover, even when all of the blades assembled onto a rotor are notcoated with the hard material, as long as some of the blades are coatedwith the hard material, then it is still possible to obtain the effectas if all of the blades were coated. This principle also applies to theannular seal as long as one or more portions on the circumference of theannular seal have the abrasive properties.

FIG. 11 is a schematic diagram of a labyrinth seal structure accordingto an eighth embodiment of the rotating member of the present invention,and FIG. 12 is a front view of the labyrinth seal of FIG. 11. FIG. 13 isa schematic diagram of a discharge processing machine according to theeighth embodiment of the coating method according to the presentinvention.

As shown in FIGS. 11 and 12, a labyrinth seal structure 31, according toan embodiment of the present invention, is used in the gas turbine of ajet engine and inhibits a leak of combustion gas between an enginestationary component 33 and an engine rotating component 35. Thelabyrinth seal structure 31 includes, as constituting elements, ahoneycomb-shaped stationary-side honeycomb seal component 37 integrallydisposed on the engine stationary component 33, and a rotating/rotatablelabyrinth seal component 39 disposed inside the stationary-sidehoneycomb seal component 37 and capable of rotating integrally with theengine rotating component 35. It is to be noted that a stationary-sideabradable seal component, whose inside is coated with the abradablecoat, may also be used instead of the stationary-side honeycomb sealcomponent 37.

A concrete example of the rotating/rotatable labyrinth seal component39, which is an important part of an embodiment of the presentinvention, is as follows. Specifically, an annular seal component mainbody 41, which is a main body of the rotating/rotatable labyrinth sealcomponent 39, is integrally disposed on the engine rotating component35, and a plurality of annular seal fins 43 are integrally formed on theouter peripheral surface of the seal component main body 41. Tip edgesof the respective seal fins 43 are coated with coats 45 of the hardmaterial. Furthermore, for forming each coat 45 of hard material, anelectrode 47 for coating having consumability (see FIG. 13) is used, anda pulsed discharge is caused between the electrode 47 for coating andthe tip edge of the seal fin 43. The constituting material of theelectrode 47 for coating, or the reactant of the constituting material,forms into the coating film containing the hard material on a pluralityof treated portions in the tip edges of the seal fins 43 due to thedischarge energy. Accordingly, a plurality of (four in the embodiment ofthe present invention) local coats 45 a of hard material are applied atequal intervals.

In this disclosure, in accordance with the embodiments of the presentinvention, in general, the phrase “the electrode for coating havingconsumability” means a green compact electrode (including a thermallytreated green compact electrode) obtained by compression molding of apowdered metal (including a metal compound), a mixed material of thepowdered metal and a powdered ceramic, or the powdered ceramic havingconductivity. The phrase “the electrode for coating havingconsumability” may also mean a silicon electrode formed of solidsilicon. It is to be noted that ceramic having conductivity may besubjected to a surface treatment for forming a conductive coating filmon the ceramic powder, and molded by compression, so that conductivityis secured. Especially, examples of the “powdered metal” include Ti, Co,and the like, and examples of the “powdered ceramic” include cBN, TiC,TiN, TiAlN, AlN, TiB₂, WC, Cr₃C₂, SiC, ZrC, VC, B₄C, Si₃N₄, ZrO₂—Y,Al₂O₃, and the like, in accordance with the present invention.

The examples of the material that reacts by discharge energy to form thecoating film containing hard material include Ti, W, Cr, Zr, Si, V, Mo,Nb. Furthermore, the electrode 47 for coating has a shape approximate tothat of the portion to be treated in the tip edges of the seal fins 43.

Next, a concrete example of a discharge processing machine 49, for usein coating the coat 45 of hard material, and a coating method forcoating the coat 45 of hard material, will be described with referenceto FIG. 13. Specifically, in a discharge processing machine 49,according to an embodiment of the present invention, a bed 51 is used asthe processing machine base, and a table 53 is disposed on the bed 51.The table 53 can be moved in X-axis directions (i.e., left and rightdirections shown in FIG. 13) by driving an X-axis servo motor (notshown), and can be moved in Y-axis directions (i.e., front and backdirections of a sheet surface of FIG. 13) by driving a Y-axis servomotor (not shown). A processing tank 55 in which dielectric liquid L(such as dielectric oil) is disposed on the table 53, and a supportplate 57 is disposed in the processing tank 55. A support tool 59, towhich the seal component main body 41 is fixed, is disposed on thesupport plate 57. A processing head 61 is disposed via a column (notshown) above the bed 51 (above in FIG. 13), and this processing head 61can move in Z-axis directions (i.e., upward and downward directionsshown in FIG. 13) by driving a Z-axis servo motor. Moreover, anelectrode hold member 63 for holding the electrode 47 for coating isdisposed on the processing head 61.

It is to be noted that the electrode hold member 63 and the support tool59 are electrically connected to a power supply 65. Therefore, the sealcomponent main body 41 is fixed by the support tool 59 in a state inwhich a portion of the tip edge of the seal fin 43 to be treated in theperipheral direction is directed right upwards in the processing tank55. Next, the table 53 is moved in the X-axis and Y-axis directions (atleast either one of these directions) by driving the X-axis and Y-axisservo motors. In this way, the position of the seal fin 43 is determinedsuch that the portion of the tip end of the seal fin 43 to be treatedfaces the electrode 47 for coating. Moreover, the electrode 47 forcoating is moved integrally with the processing head 61 in the Z-axisdirection by driving the Z-axis servo motor, while a pulsed voltage isgenerated between the electrode 47 for coating and the portion of thetip end of the tip fin 43 to be treated in the dielectric liquid L.Accordingly, the electrode material of the electrode 47 for coating islocally diffused in, and/or welded to, the portion of the tip edge ofthe seal fin 43 to be treated by discharge energy, and the portion ofthe tip edge of one seal fin 43 to be treated can locally be coated witha local coat 45 a of hard material.

Furthermore, when the table 53 is moved in the Y-axis directions bydriving the Y-axis servo motor, the position of another seal fin 43 isdetermined such that the portion of the tip fin of the seal fin 43 to betreated faces the electrode 47 for coating. Then, as described above,the electrode material of the electrode for coating 47 is locallydiffused in, and/or welded to, the portion of the tip edge of this sealfin 43 to be treated by discharge energy, and the portion of the tipedge of the seal fin 43 to be treated is locally coated with the localcoat 45 a of hard material.

After locally coating the portion of the tip edge of a plurality of theseal fins 43 to be treated with the local coat 45 a of hard material, asimilar operation is repeated. In this way, also other portions of thetip edges of a plurality of the seal fins 43 to be treated are alsolocally coated with the local coats 45 a of hard material.

Next, the function of an embodiment of the present invention will bedescribed. The rotating/rotatable labyrinth seal component 39 includesthe coat 45 of hard material. Therefore, by integrally rotating therotating/rotatable labyrinth seal component 39 and the engine rotatingcomponent 35, even when the engine stationary component is deformed andthe rotating/rotatable labyrinth seal component 39 contacts with thestationary-side honeycomb seal component 37, the stationary-sidehoneycomb seal component 37 is only shaved by the coat 45 of hardmaterial in the rotating labyrinth seal component 39. Therotating/rotatable labyrinth seal component 39 is substantially hardlyshaved at all.

Accordingly, the clearance between the stationary-side honeycomb sealcomponent 37 and the rotating/rotatabel labyrinth seal component 39 isinhibited from increasing during rotation of the engine rotatingcomponent 35, and the seal effect of the labyrinth seal structure 31 canbe kept in an appropriate state (i.e., optimized). Therotating/rotatable labyrinth seal component 39 is set beforehand so asto slightly contact the stationary-side honeycomb seal component 37 atthe time of the initial rotation of the engine rotating component 35.Accordingly, the clearance between the stationary-side honeycomb sealcomponent 37 and the rotating/rotatable labyrinth seal component 39 canbe set to be as small as possible during, and after, the initialrotation and the seal effect of the labyrinth seal structure 31 canfurther be enhanced.

Moreover, coating of the coats 45 of hard material is performed onportions of the tip edges of the seal fins 43 by diffusing and/orwelding electrode material of the electrode 47 for coating by dischargeenergy generated between the electrode for coating 47 and the portion ofthe tip edge of the seal fin 43, which is performed without performingplating or thermal spraying. Therefore, during production of therotating/rotatable labyrinth seal component 39, the coatingpost-treatments (such as the blast treatment and the process of removingmasking tape) are unnecessary.

Furthermore, the boundary portion between the coat 45 of hard materialformed by discharge energy and the mother body of the seal fin 43 hasalloy composition changing properties, and the coat of hard material canbe firmly connected to the tip edge of the seal fin 43. Moreover, thecoat 45 of hard material includes a plurality of local coats 45 a ofhard material. In other words, the electrode material 47 of theelectrode for coating is locally diffused in, and/or welded to, aplurality of portions to be treated along the peripheral direction inthe tip edge of the seal fin 43, but not along the whole periphery ofthe tip edge of the seal fin 43. Therefore, the electrode 47 for coatingcan be formed to have a small and simple shape in accordance with thesize and/or the shape of the portion of the tip edge of the seal fin 43to be treated. Accordingly, the amount of the electrode material used toform the electrode 47 for coating can be reduced.

It is to be noted that as described above, the coat 45 of hard material(i.e., local coat 45 a of hard material) can be connected firmly to thetip edge of the seal fin 43. Therefore, even when the entire tip edgeperiphery of the seal fin 43 is not coated with the coat 45 of hardmaterial, sufficient abrasive properties of the entirerotating/rotatable labyrinth seal component 39 can be achieved by theplurality of local coats 45 a of hard material.

As described above, according to an embodiment of the present invention,during production of the rotating/rotatable labyrinth seal component 39,the coating pretreatments (such as the blast process and the process ofattaching the masking tape), and the coating post-treatments (such asthe process of removing the masking tape) are not required. Therefore,the operation time required for production of the rotating/rotatablelabyrinth seal component 39 is reduced, and it is easy to enhance theproductivity yield of the rotating/rotatable labyrinth seal components39. Moreover, because the coat 45 of hard material can be connectedfirmly to the tip edge of the seal fin 43, the coat 45 of hard materialdoes not easily peel off from the tip edge of the seal fin 43, and thequality level of the rotating labyrinth seal component 39 is stabilized.

Furthermore, the entire rotating/rotatable labyrinth seal component 39has sufficient abrasive properties, and the electrode 47 for coating canbe formed to have a small and simple shape in accordance with thesize/shape of the portion to be treated of the tip edge in the seal fin43. Moreover, the amount of the electrode material used to form theelectrode for coating 47 can be reduced. Therefore, the production costof the rotating/rotatable labyrinth seal component 39 can be reduced.

It is to be noted that the present invention is not limited to thedescription of the embodiments of the present invention. For example,instead of performing the discharge in the dielectric liquid L, thedischarge can be performed in an electrically insulating gas. Thus,various modifications can be carried out within the scope of the presentinvention.

As described above, according to the present invention, duringproduction of the rotating/rotatable labyrinth seal component, thecoating pretreatments, such as the blast process and the process ofattaching masking tape, and the coating post-treatments, such as theprocess of removing the masking tape, are not required. Therefore,operation time required for production of the rotating/rotatablelabyrinth seal component is reduced, and it is easy to enhance theproductivity yield of the rotating/rotatable labyrinth seal components.

Moreover, because the coat of hard material can be firmly connected tothe tip edge of the seal fin, the coat of hard material does not easilypeel off from the tip edge of the seal fin, and the quality level of thelabyrinth seal is stabilized.

Furthermore, in addition to the above-described effect, the entirerotating/rotatable labyrinth seal component has sufficient abrasiveproperties, and the electrode for coating can be formed to have a smalland simple shape in accordance with the size/shape of the portion to betreated at the tip edge in the seal fin. Moreover, the amount ofelectrode material used to form the electrode for coating can bereduced. Therefore, the production cost for the rotating/rotatablelabyrinth seal component can be reduced.

It is to be noted that some preferable embodiments of the presentinvention have been described, but it would be understood that the scopeof the present invention is not limited to these embodiments.Conversely, the scope of the present invention includes allimprovements, modifications, and equivalents included in the appendedclaims.

The method in which the electrode is formed by compression molding ofpowder using a press is described in the above. However, it is apparentthat the method for forming the electrode is not limited to thecompression molding as long as the electrode is formed by using powder.As a method for forming the electrode, there are a method that usesslip, a method that uses an MIM (Metal Injection Molding), a method thatuses thermal spraying, a method that uses nano powder accompanying a jetstream, and the like. In the method that uses slip, powder is dispersedin a solvent, and the solution is put in a porous mold such as gypsum toremove the solvent so that the electrode can be molded. In the methodthat uses the MIM, a mixture of powder and binder is kneaded, and theninjected into a heated mold. In the method that uses thermal spraying,heated powder is sprayed to combine a part of the sprayed powder,forming the electrode. These methods are different in a manner offorming the electrode, but a purpose of these methods is the same interms of forming the electrode by using powder. In other words, when thecombination of powder reaches a desired state, the combined powder canbe then used as the electrode.

1. A method for coating a rotatable member of a turbine or a compressorwith an abrasive coating film in order to minimize clearance between therotatable member and an opposite component of the turbine or thecompressor, the method comprising the steps of: (a) generating a pulseddischarge between a rotatable member formed into a predetermined shapeand a first discharge electrode in a dielectric liquid or gas, whereinthe first discharge electrode is a green compact electrode; (b)transferring a first coating material from the first discharge electrodeonto the rotatable member by each discharge pulse so that the abrasivecoating film is formed on the rotating member, wherein when the abrasivecoating film formed by the first coating material rubs against theopposite component the abrasive coating film shaves the oppositecomponent, wherein the green compact electrode includes the firstcoating material or a second material that changes into the firstcoating material due to the discharge, and the first coating material isone of, or a mixture of, cBN, TiC, TiN, TiAlN, TiB₂, WC, Cr₃C₂, SiC,ZrC, VC, B₄C, Si₃N₄, ZrO₂—Y, and Al₂O₃, and the second coating materialis one of Ti, W, Cr, Zr, Si, V, Mo and Nb; (c) forming, on the rotatablemember, the abrasive coating film by repeatedly generating the dischargepulse, wherein the rotatable member is a turbine blade, a compressorblade or a labyrinth seal; and (d) deploying the rotatable member in theturbine or the compressor, wherein the rotatable member is disposed sothat there is a clearance between the rotatable member and the oppositecomponent of the turbine or the compressor so that the abrasive coatingfilm shaves the opposite component when the abrasive film rubs againstthe opposite component thereby minimizing the clearance between therotatable member and the opposite component.
 2. The method for coatingthe rotatable member according to claim 1, further comprising the stepsof: generating discharge between the rotatable member and the firstdischarge electrode on a first discharge condition on which a portion ofthe first discharge electrode is consumed so that a shape of the firstdischarge electrode is made to conform to a shape of a coating filmforming portion on the rotatable member; and thereafter generatingdischarge between the first discharge electrode and the rotatable memberon a second discharge condition to form the abrasive coating film on therotatable member.
 3. The method for coating the rotatable memberaccording to claim 2, wherein on the first discharge condition, thefirst discharge electrode has a minus polarity, a pulse width is 1 μs orless, and a current value is 10 A or less, and on the second dischargecondition, the first discharge electrode has a minus polarity, the pulsewidth is 2 to 10 μs, and the current value is 5 to 20 A.
 4. The methodfor coating the rotatable member according to claim 1, wherein at thetime of forming the coating film, a porous coating film is formed as abase film on the rotatable member by using a second discharge electrodeother than the first discharge electrode, wherein the second dischargeelectrode is made of metallic material, and then, the abrasive coatingfilm including the first coating material is formed on the porouscoating film.
 5. The method for coating the rotatable member accordingto claim 1, further comprising the step of peening the abrasive coatingfilm so that a surface of the abrasive coating film is stretched bypeening while compression stress is left in the abrasive coating film.6. The method for coating the rotatable member according to claim 1,wherein the abrasive coating film has a surface roughness that iscoarser than 1.2 μmRa.
 7. The method for coating the rotatable memberaccording to claim 1, wherein a ratio of coverage of coated portion touncoated portion of an area coated with the coating film in a coatingfilm forming portion of the rotating member is not more than 95% of thearea coated, and the uncoated portion of the coating film portion isscattered within the area coated with the coating film.
 8. The methodfor coating the rotatable member according to claim 1, wherein a ratioof coverage of coated portion to uncoated portion of an area coated withthe coating film in a coating film forming portion of the rotatingmember is about 95% of the area coated, and the uncoated portion of thecoating film portion is scattered within the area coated with thecoating film.
 9. A method for manufacturing a rotatable member of ablade or a labyrinth member employed in a turbine or a compressor, themethod comprising the steps of: (a) forming a forged material or acasted material into a predetermined shape by mechanical processing; (b)generating a pulsed discharge between a rotatable member formed into apredetermined shape and a first discharge electrode in a dielectricliquid or gas, wherein the first discharge electrode is a green compactdischarge electrode formed by compression molding of one of, or amixture of, cBN, TiC, TiN, TiAlN, TiB₂, WC, Cr₃C₂, SiC, ZrC, VC, B₄C,Si₃N₄, ZrO₂—Y, and Al₂O₃, or one of Ti, W, Cr, Zr, Si, V, Mo and Nb; (c)transferring a first coating material from the first discharge electrodeonto the rotatable member by each discharge pulse so that an abrasivecoating film formed by the first coating material is formed on therotatable member, wherein the green compact includes the first coatingmaterial or a second material changing into the first coating materialdue to the discharge; (d) forming, on the rotatable member, an abrasivecoating film by repeatedly generating the discharge pulse, wherein therotatable member is a turbine blade, a compressor blade or a labyrinthseal; and (e) employing the rotatable member in the turbine or thecompressor, wherein the rotatable member is disposed so that there is aclearance between the rotatable member and an opposite component of theturbine or the compressor so that the abrasive coating film shaves theopposite component when the abrasive film rubs against the oppositecomponent thereby optimizing the clearance between the rotatable memberand the opposite component.
 10. The method for manufacturing therotatable member according to claim 9, wherein step (b) furthercomprises the steps of: generating discharge between the rotatablemember and the first discharge electrode on a first discharge conditionon which a portion of the first discharge electrode is consumed so thata shape of the first discharge electrode is made to conform to a shapeof a coating film forming portion on the rotating member; and thereaftergenerating discharge between the first discharge electrode and therotatable member on a second discharge condition to form the abrasivecoating film on the rotatable member.
 11. The method for manufacturingthe rotatable member according to claim 10, wherein on the firstdischarge condition, the first discharge electrode has a minus polarity,a pulse width is 1 μs or less, and a current value is 10 A or less, andon the second discharge condition, the first discharge electrode has aminus polarity, the pulse width is 2 to 10 μs, and the current value is5 to 20 A.
 12. The method for manufacturing the rotatable memberaccording to claim 9, wherein step (b) further comprises the steps of:forming a porous coating film on a coating film forming portion of therotatable member by using a second discharge electrode other than thefirst discharge electrode, wherein the second discharge electrode ismade of metallic material; and thereafter forming the abrasive coatingfilm on the porous coating film.
 13. The method for manufacturing therotatable member according to claim 9, further comprising the step of:subjecting the abrasive coating film formed in step (b) to a peeningtreatment so that a surface of the abrasive coating film is stretched bypeening while compression stress is left in the abrasive coating film.14. The method for coating the rotatable member according to claim 9,wherein a ratio of coverage of coated portion to uncoated portion of anarea coated with the coating film in a coating film forming portion ofthe rotating member is not more than 95% of the area coated, and theuncoated portion of the coating film portion is scattered within thearea coated with the coating film.
 15. The method for coating therotatable member according to claim 9, wherein a ratio of coverage ofcoated portion to uncoated portion of an area coated with the coatingfilm in a coating film forming portion of the rotating member is about95% of the area coated, and the uncoated portion of the coating filmportion is scattered within the area coated with the coating film.
 16. Amethod for manufacturing a rotatable member of a blade or a labyrinthmember employed in a turbine or a compressor, the method comprising: afirst step of forming a forged material or a casted material into apredetermined shape by mechanical processing; a second step ofgenerating a pulsed discharge between a rotatable member formed into apredetermined shape and a discharge electrode in a dielectric liquid orgas, wherein the discharge electrode is a green compact; a third step oftransferring a first coating material from the discharge electrode ontothe rotatable member by each discharge pulse so that an abrasive coatingfilm formed by first coating material is formed on the rotatable member,wherein the green compact includes the first coating material or asecond material changing into the first coating material due to thedischarge, and the first coating material is one of, or a mixture of,cBN, TiC, TiN, TiAlN, TiB₂, WC, Cr₃C₂, SiC, ZrC, VC, B₄C, Si₃N₄, ZrO₂—Y,and Al₂O₃, and the second coating material is one of Ti, W, Cr, Zr, Si,V, Mo and Nb; a fourth step of forming, on the rotatable member, theabrasive coating film by repeatedly generating the discharge pulse,wherein the rotatable member is a turbine blade, a compressor blade or alabyrinth seal; and a fifth step of employing the rotatable member inthe turbine or the compressor, wherein the rotatable member is disposedso that there is a clearance between the rotatable member and anopposite component of the turbine or the compressor so that the abrasivecoating film shaves the opposite component when the abrasive film rubsagainst the opposite component thereby optimizing the clearance betweenthe rotatable member and the opposite component.
 17. The method forcoating the rotatable member according to claim 16, wherein a ratio ofcoverage of coated portion to uncoated portion of an area coated withthe coating film in a coating film forming portion of the rotatingmember is not more than 95% of the area coated, and the uncoated portionof the coating film portion is scattered within the area coated with thecoating film.
 18. The method for coating the rotatable member accordingto claim 16, wherein a ratio of coverage of coated portion to uncoatedportion of an area coated with the coating film in a coating filmforming portion of the rotating member is about 95% of the area coated,and the uncoated portion of the coating film portion is scattered withinthe area coated with the coating film.